Folded expand-on-site paper packaging

ABSTRACT

A series of interconnected packing chip precursors that can be formed and transported economically to a packager as a flat sheet and then expanded at the site where they will be used into individual packing chips by folding and separation from the other chips. Preferably, the precursors are formed on a chipboard sheet by forming fold lines and lines of separation and by adding securing means, such as bonding media or connecting features to secure the sides of the expanded packing chip in its final shape. The fold lines and lines of separation can be configured to form jagged or serrated edges on the expand-on-site packing chip, and the chip may also include apertures; the jagged and serrated edges and the apertures cooperating with each other and other aspects of adjacent chips to interlock the chips when they are placed around an item in a package for shipment.

I. FIELD OF THE INVENTION

[0001] The present invention relates generally to loose fill packingmaterials or “dunnage,” as these materials are sometimes referred to.Traditionally these materials have often been supplied in the form ofpre-expanded packing “chips,” such as plastic “peanuts.” Morespecifically, the invention relates to: (1) compact sheets of chipprecursors which can be shipped and stored more economically and (2)packing chips which can be formed by folding or expanding the chipprecursors at the place where the packing chips will be used.

II. BACKGROUND OF THE INVENTION

[0002] Experience indicates that a packing material must have a numberof important attributes including:

[0003] 1. Cushioning Properties: The packaging material must providecushioning for packaged items to protect them during shipment. Thecushioning must dissipate or diffuse the shock loads imposed on thepackaging container (typically a “box”) during shipment so that thoseloads are not applied to the packaged item directly. It is alsoimportant that the packaging material have high rebound characteristics(within its usable range) so that it can continue to provide cushioning,as loads are repeatedly applied. Different items packed for shipment mayrequire different degrees of stiffness to adequately protect them.

[0004] 2. Blocking and Bracing Properties: The ability of the packagingmaterial to “block and brace” refers to its capability to preventmovement of the packaged item within the container so that the packagingcan cushion that item. If a packed item is allowed to move against thewall of the container, with no cushioning in between, then it will bedirectly subjected to any shock loads applied to the outside of the boxadjacent that location.

[0005] 3. Ease of Use: The packing material must be easy to use in orderto minimize the labor required to pack an item. In particular, thepacking material should be capable of being easily and quicklypositioned around the packed item.

[0006] 4. Storage of packaging materials: The physical form that apackaging material is stored in is an important attribute. Packagingmaterials generally fall into two categories:

[0007] a) “Pre-expanded” materials—like plastic peanuts or bubblesheets—are supplied by the manufacturer to the packager in final form.

[0008] b) “Expand-on-site” materials are supplied to the packager in adense, un-expanded condition. The packaging is expanded into its finalform at the packager's site. Prior art systems have utilized inflation,or wadding and crumpling to produce expanded packaging from flatmaterials. The formation of foam packaging on site may also be includedin this category of expand-on-site materials. Expansion ratios vary fromabout 10:1 for wadded Kraft paper cushioning to as much as 50:1 forexpanding foams. Expand-on-site materials enjoy a large advantage, sincethey do not occupy highly valued inventory space at the packager'sfacility and have much lower costs for shipping to the packager.

[0009] 5. Economics: The packaging material must be competitive in pricewith other materials that provide the same level of protection. Laborand shipping charges (to get the material to the packager) can be asignificant percentage of the total cost-of packaging products.Pre-expanded materials necessarily entail higher shipping charges thanexpand-on-site materials whose useful volume is created at the packager.

[0010] 6. Creation of Dust: The packaging material must not create dustor other debris that will stick to the packaged item and make itunsightly for the recipient. This is a particular problem withuncompressed materials molded from a cellulose slurry that have roughsurfaces and edges from which small particles will be separated in thecourse of normal handling and use.

[0011] 7. Density: The packaging material must be as lightweight aspossible to minimize shipping charges for the packaged item. Generally,these shipping charges are based on the weight of the package and itscontents.

[0012] 8. Environmental Friendliness: Packaging materials made fromplastics or toxic, two-part, expanding foams have a disadvantage in themarketplace as compared to paper-based products, because they do notquickly biodegrade in the same environmentally friendly way that paperbased products do. In addition, recipients of packaged items generallyprefer paper-based packaging due to the negative environmental image ofplastic based materials.

[0013] 9. “Flowability” and Associated Side-effects: Flowable packagingmaterials, such as plastic “peanuts,”are in wide use today, because theysubstantially reduce labor costs associated with packing. Highly“flowable” packaging materials may be poured and placed into a shippingcontainer quickly. They also do not require wrapping, taping or otherlabor-intensive operations as with many other packing materials.However, flowables (i.e., loose format packaging materials) have notprovided adequate blocking and bracing characteristics. Plastic peanuts,for example, exhibit good cushioning properties but have such poorblocking and bracing characteristics that the packaged item moves aroundin the container or box. When the packaged item reaches a wall of thecontainer, it is no longer protected by the packaging material and issusceptible to being broken when the package receives an external blow.By definition, “flowables” flow easily into the box during packing, butalso flow inside the box after packing, allowing movement of thepackaged item. The exception to this are E-Cubes® packing chips, whichare described in U.S. Pat. No. 5,900,119. E-Cubes® packing chips werethe first flowable packaging material that had good blocking and bracingproperties. This was accomplished with a combination of shape andtexture which permits interlocking of the chips after they are placedaround a packaged item.

[0014] No packing material commercially utilized to date has satisfiedall of these characteristics. In summary, the ideal packaging productwould:

[0015] 1. Be a flowable to make packing fast and economical;

[0016] 2. Have good cushioning and blocking and bracing properties;

[0017] 3. Be an expand-on-site type material using simple reliablemachinery;

[0018] 4. Be made from recycled paper and be recyclable to protect theenvironment;

[0019] 5. Minimize the costs of shipping both to the packager and therecipient of a packaged item; and

[0020] 6. Be clean so that dust or other debris are not generated duringuse and are not transferred to the item being shipped.

III. SUMMARY OF THE INVENTION

[0021] A new packaging material has been invented that has all of thesecharacteristics. The packaging is a flowable and is made from a materialcommonly known as “chipboard.” Chipboard is produced by paper millsworldwide and is usually comprised of 100% recycled content. Thechipboard is modified into an expand-on-site packaging material byadding fold lines, cutouts, perforations and/or perforation lines to theflat chipboard. Binding media, e.g., an adhesive, may also bepre-applied to appropriate portions of the expand-on-site material. Themodified chipboard can be stacked, rolled or fan-folded for shipment tothe packager. This significantly reduces transportation costs andcustomer inventory space/cost requirements.

[0022] When the packager wishes to use the expand-on-site material, itremoves the appropriate quantity of chip precursors from inventory,folds or expands the precursors into the shape of the packaging materialand secures it in that shape. These steps can be performed manually orby machine. In either method appropriate portions of the expand-on-siteprecursor material are separated from the other intermediates and areformed it into the final shape of the packaging material. Adhesive onmating sections of each chip is activated to hold the material in itsfinal shape. The assembly may be done at or near the actual packagingstation where the packaging material will be placed around an item to beshipped in its shipping container. The chips could also be supplied tothe packager pre-expanded and ready for use.

[0023] The invention described herein relates to an improved,expand-on-site packaging material in its intermediate (i.e., precursor)and final (i.e., expanded) forms and the methods of making both theexpand-on-site and expanded materials.

IV. BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 is an illustration of a preferred intermediate sheetcontaining packing chip precursors in a form suitable for delivery to apackager.

[0025]FIG. 2 is an illustration of the features of a single chipprecursor on the intermediate sheet depicted in FIG. 1.

[0026]FIG. 3 is an illustration of the completed packaging material,i.e., as expanded by the packager from the intermediate shown in FIG. 1.The chip illustrated in FIG. 3 has a preferred cross-section in the formof a triangle.

[0027]FIG. 4 illustrates the configuration of a double row of chips fromthe intermediate in FIG. 1 in the process of being transformed intoseveral chips of the type shown in FIG. 3.

[0028]FIG. 5 is a perspective view of another embodiment of the presentinvention in which the completed packing material has a circularcross-section. FIGS. 5A and 5B show end views of the same packing chip.In FIGS. 5 and 5A, the chip is secured with a butt joint. In FIG. 5B,the chip is secured with a lap joint.

[0029]FIG. 6 illustrates a preferred configuration of the intermediatefrom which the circular packing chip of FIG. 5 is prepared.

V. DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED EMBODIMENT

[0030] Among other things, the present invention includes a packing chipformed from a flat intermediate sheet containing two or more chipprecursors, where the chip comprises: sides configured so that thepacking chip has a cross-section selected from the group consisting of atriangle, circle or polygon, and securing means for securing the sidesof the chip in its final shape.

[0031] The invention also includes an intermediate sheet of two or morepacking chip precursors capable of being formed into expanded packingchips, each chip precursor being separably connected to at least oneadjacent chip precursor and comprising: one or more sections each ofwhich is foldably attached to at least one other section which uponfolding form the sides of the expanded packing chip; and securing meansselected from the group consisting of bonding media or connectingfeatures for securing the sides of the expanded packing chip in itsexpanded shape. Further, the invention includes a method for forming anintermediate sheet of two or more packing chip precursors comprising:forming, lines of separation to separably connect each chip to theadjacent chips on said intermediate sheet; forming at least threesections on each chip by creating fold lines between said sections, andadding one or more securing means selected from the group consisting ofbonding media and connecting features to secure the sides in their finalform when expanded.

[0032] Finally, the invention comprises a method for forming anexpand-on-site packing chip from an intermediate sheet containing two ormore chip precursors comprising: folding the precursor into at leastthree sections to form the sides of the expanded packing chip; attachingthe sides of the expanded packing chip; and separating the expanded chipfrom the adjacent chip or chips

[0033] The invention can best be understood by reference to FIGS. 1 and2 illustrating an expand-on-site intermediate material made fromchipboard and FIG. 3 illustrating the packing chip produced from theintermediate in its expanded form.

[0034] As noted previously “chipboard” is made by a number of papermanufactures, for example, Republic Paperboard Company, Hutchinson,Kansas. Chipboard is a thin smooth-finished, material made from recycledpaper and typically provided in the form of a continuous roll. Chipboardgenerally connotes a low grade of stiff paper or cardboard and isfrequently used as a backing for pads of paper, a stiffener for themailing or framing of photographs and for other similar uses. However,to the best of applicants' knowledge “chipboard” has not previously beenemployed to form packing chips, and its name should not be construed tosuggest a prior association of that material with this use. Applicantshave now found that chipboard is a good starting material to producepacking chips, because of its low cost, strength and stiffness. Specificmaterials employed to date include Republic Paperboard's “24-point corestandard,” “20-point tan bending stock” and “18 point brown bendingchipboard.” Other thicknesses and types of chipboard and other materialsmeeting these requirements might be used, such as, Kraft paper.Synthetic or plastic materials might also be used, especially wherewaterproof, fireproof or chemically resistant packaging is required.

[0035]FIG. 1 illustrates one preferred embodiment of the invention inwhich continuous chipboard sheet 1 is processed into continuous sheet 2of expand-on-site chip intermediates or precursors. As illustrated inFIG. 1, sheet 2 comprises two rows of such chips—one row comprisingchips 5A, 6A and 7A, which are abutted by an adjacent row of chips 5B,6B and 7B. However, depending on the width of the chipboard 1, a singlerow of such chips or any number of adjacent rows of chips can be formedside-by-side on sheet 2. Regardless of the number of rows, it ispreferred that the chip precursors formed on the sheet of chipboard allremain attached to one another until expanded and separated by thepackager.

[0036] Typically, chipboard sheet 1 is provided from the mill in rolledor fan-folded form. The sheet is unrolled and processed continuously byan intermediate “converter” which has stations to make perforations orlines of weakness for folding or separation, as necessary, and formaking holes or other apertures in the chip precursors. In addition, theconverter may add bonding media, such as adhesive, or connectingfeatures at appropriate places. The sequence in which these steps areperformed may be varied depending on the design of the chip precursorsand their arrangement on sheet 2. It is anticipated that machinesnormally employed in the manufacturer of forms or mailers, as well asmachines used to make beverage cartons, can be used in the production ofintermediate sheet 2 as described herein. All or part of the stepsperformed by the converter may be performed at the site where thechipboard is made and/or at the site of an intermediate manufacturer.They might also be performed at the site of the ultimate packager, ifthe volume of chips employed by the packager justifies the capitalexpense. In the preferred embodiment described herein, all of thestructural features of the intermediate are preformed, and theintermediate is delivered to the packager ready for final expansion andseparation into individual packaging chips.

[0037] In the preferred embodiment shown in FIG. 2, chip 5A comprisessections, 12, 13 and 14, which are bounded by jagged fold lines 20 and30. Fold line 20, for example, is made by the converter with sufficientpenetration of the chipboard to facilitate folding and partialseparation of sections 12 and 13 during expansion by the expandingmachine except at common shoulders 21, where the two adjacent sectionsare folded but remain attached. (See FIG. 3) Similarly, fold line 30enables eventual partial separation of sections 13 and 14, except atshoulders 31. (See FIG. 3) In addition, a fold line 10 is formed on oneportion of section 12 to form a tab 11 between edge 15 and section 12.Bonding media 17 can be applied to the tab 11 and/or to the matingbonding area 19 for securing the expanded chip in its final shape, shownin FIG. 3.

[0038] As shown in FIG. 1, the converter adds a perforation line 8Xbetween chips 5 (A, B) and 6 (A, B) to enable them to be completelyseparated from one another prior to, during or after the expansion step,as necessary. The separation between chips 5B and 6B is accomplished,for example, by bursting shoulders 22. A similar line 8W may be added tothe front of chips 5A and 5B, which as shown are the leading chips onthe sheet 2. Similarly, a perforation line 8Y is formed between chips 6(A, B) and 7 (A, B). Again, the separation between chips 6B and 7B canbe accomplished by bursting shoulders 32. As illustrated in the drawing,lines 8W, 8X, 8Y and 8Z are zigzag in configuration, so that the edgesformed on the separated and expanded chips will be jagged or serrated,thereby providing appropriate irregular surfaces for interlocking withother fully expanded chips when used as packaging. The lines 8W, 8X, 8Yand 8Z could be formed in other configurations that would accomplish thesame result.

[0039] Similarly, the intermediate converter forms a line of weakness 16between the chips in row A (i.e., chips 5A, 6A and 7A) and the chips inrow B (i.e., chips 5B, 6B and 7B). The chips in each row may beseparated from the adjacent chip in the other by bursting line ofweakness 16. Again, line 16 has a zigzag configuration, so that thisedge of each chip after separation will be jagged or serrated to aid ininterlocking of the expanded chips.

[0040] The intermediate converter also adds apertures, such as holes 40,at various locations on each chip precursor. Usually, it is desirable toboth cut the aperture and to remove the center portion of the aperturebefore shipment of the intermediate to the packager. This reduces theshipping weight of intermediate 2. Alternatively, the holes 40 can bepreformed by the converter, and the center portion removed or justfolded in during expansion-on-site. The apertures or holes 40 shown inthe drawings are circular, but can be any shape, e.g., triangular,square or star shaped in configuration. There may be multiple holes ineach section to decrease weight and increase interlocking of the chips.As described later, the holes interlock with jagged or serrated portionson adjacent chips after the chips are applied around a packaged item tobe shipped, thereby providing improved blocking, bracing and cushioningcharacteristics during shipment.

[0041] The bonding media 17 may be a polymer or any suitable adhesivesuch as thermosetting, microwave-activated, ultrasonic-activated,wettable or pressure activated types that are suitable depending uponthe conditions of storage and use. The adhesive can be applied directlyto the intermediate 2 or supplied in the form of a transfer tape. Theadhesive should be selected and/or located so that adjacent segments ofintermediate 2 will not bond to one another causing “bricking” after thesheet 2 is rolled or fan-folded for shipment to the packager.Technologies for doing this are well known to those skilled, forexample, in the art of manufacturing mailers and forms with adhesivesapplied to various portions. At the present time it is anticipated that“hot melt,” i.e., thermosetting, adhesives are preferable, because theyare relatively easy to activate when desired, do not result in brickingof the intermediate when rolled or folded on itself under normalconditions of use, and form a secure bond after curing to maintain thestructure of the expanded packing chip.

[0042] Although the bonding media is shown in FIG. 1 as being located onthe entire portion of tab 11 and on mating area 19, the adhesive couldbe located on only a portion of those areas either in a continuous lineor in spots in order that the objectives mentioned previously are metwhile minimizing cost.

[0043] If a plastic or other synthetic material is used instead ofchipboard, adhesive need not be employed. Instead, bonding of the fullyexpanded chips can be accomplished by the application of pressure and/orheat, ultrasonic energy, solvent, or microwave energy during theassembly of the chips.

[0044] As an alternative to bonding media, the converter may addfeatures to tab 11 and area 19 to form connecting features tomechanically hold the fully expanded chip in shape. These connectingfeatures may include; dovetail slots and grooves, tongue and groovecuts, hook cuts and combinations thereof. These features are “snapped”together to secure the sections of the chips and thereby maintain thechips in their expanded form. Alternatively, attachment methods, such ascrimping, stapling, etc., can be utilized after expansion of theprecursor to hold the chip in its final shape.

[0045] As used herein “securing means” collectively refers to bondingmedia, connecting features and attachment methods.

[0046] After preparation by the converter, intermediate sheet 2 of chips5 (A, B), 6 (A, B) and 7 (A, B), etc. may be rolled, stacked orfan-folded and transported to the packager where it is stored in thatformat until it is ready to be used.

[0047] When the packager needs packaging material, it unrolls or unfoldsthe sheet 2 and either manually expands the precursors into finishedchips or threads the sheet into the expanding machine to form individualpacking chips 50 as illustrated in FIG. 3. This can be accomplished invarious ways. In a preferred method, the machine folds along lines 10,20, and 30 to form the tab 11 and to form sides 12, 13 and 14 into atriangular shape. The folding of lines 20 and 30 forms spines orprojections 41 which are also useful for engagement and interlocking ofthe chips when used in packaging. The spines 41 are formed by partiallycutting out the material on bending comers 20 and 30 of the triangularshaped chip, so that it does not bend but protrudes from the sectionwhen the chip is expanded by folding. Heat is applied to activate thehot melt adhesive 17 on tab 11 and/or on bonding surface 19, depicted inFIG. 1. Tab 11 is then pressed against the edge portion 16 of section 14and clamped during cooling to cure the adhesive bond.

[0048] In a preferred embodiment of the invention, the assembly of chip5A occurs simultaneously with the assembly of chip 5B as they remainattached together. FIG. 4 shows these chips 5A and 5B fully formed(i.e., expanded) and bonded. A “bursting” wheel is then used to “burst”chips 5 (A, B) from chips 6 (A, B) along line 8X depicted in FIG. 1.However, chips 5A and 5B remain attached to each other along theseparation line 16. Another rotary slitter or bursting wheel is thenused for final separation of the chips 5A and 5B from each other. Thefully expanded and bonded chip 50 shown in FIG. 3 can then be used aspacking material.

[0049] The cushioning performance of this expand-on-site packaging isattributable, in part, to its shape and the properties of the materialfrom which it is made. Performance of the completed packing product 50is enhanced by engagement of the holes 40, serrated edges 8W, 8X, and 16and spines 41 interacting with one another to lock and prevent slippageof the chips relative to one another. This interlocking of the chipsalso prevents movement of the packaged item within the container.

[0050] The blocking and bracing performance of this expand-on-sitepackaging can be attributed in part to the interlocking apertures andserrated or jagged edges. If the individual chips had smooth edges, theywould readily slide on one another and would not lock with one anotherand around a packaged item. The surface of commercially availablechipboard is relatively smooth and does not create sufficient frictionbetween chips. Simply roughing up the surface would result in exposedpaper fibers that would cause dust. Instead, the expand-on-sitepackaging material has interlocking features (spines, holes and serratededges) preformed into the surface of each chip. For example, the spines41 interlock with the serrations, holes, and edges of adjacent chips.The spacing and frequency of these features may be designed to maximizeboth the likelihood of interlocking adjacent chips and the durability ofthat interlocking relationship. The combination of these featurescreates a chip that has excellent blocking and bracing characteristics.

[0051] When prepared from chipboard 0.24 inches thick, theexpand-on-site packaging material as illustrated in FIG. 3 weighs anaverage of 1.8 pounds per cubic foot. This is lighter than manycompetitive products and is considered marketable. Heavy-dutyexpand-on-site packaging material may also be produced by using heaviercaliper (i.e., thicker) chipboard for shipment of higher densitypackaged items.

[0052] As a flowable, the chips will take random orientations in theshipping container. Accordingly, it is desirable for the cushioningproperties of this packaging material to be as equal as possible in allaxes. A triangular cross section is preferred because of its inherentstructural rigidity, allowing the crushing strength of the triangularcross section, i.e., cushioning to be as close as possible to the columnstrength of the chipboard in a perpendicular axis to the cross-section.Other configurations for the chips may be employed, e.g., circular andpolygon cross-sections, but these chips are not as strong as triangularcross-sections.

[0053] For example, in FIG. 5, another embodiment of the invention isillustrated in which the packing chip of this invention has a circularcross section. Preferably, the chip is preformed along with othersimilar chips on a flat segment of chipboard as illustrated, for examplein FIG. 6. FIG. 6 shows that a continuous chipboard sheet 101 isprocessed into continuous sheet 102 of expand-on-site chipintermediates. As illustrated in FIG. 6, sheet 102 comprises two rows ofsuch chips: one row comprising chips 105A, 106A and 107A, which areabutted by an adjacent row of chips 105B, 106B and 107B. Again,depending on the width of the chipboard 101, a single row of such chipsor any number of adjacent rows of chips can be formed side-by-side onsheet 102. Regardless of the number of rows, it is preferred that thechips formed on the roll of chipboard all remain attached to one anotheruntil expanded and separated by the packager.

[0054] Chipboard sheet 101 is unrolled and processed continuously by anintermediate “converter” which has stations to make perforations orlines of weakness for folding or separation as necessary and for makingholes or other apertures in the nascent expand-on-site chip. Inaddition, the converter may add bonding media or bonding features atappropriate places.

[0055] In the preferred embodiment shown in FIGS. 5 and 6, chip 105Acomprises a single circular wall section 113 which is rolled to form achip with a circular cross-section. In this embodiment the spines locktogether primarily on themselves and the voids created by the spines.However, it is also possible to add apertures or holes in thisembodiment as well. Partial jagged lines, such as 120 and 130, areformed on the wall section 113 at various intervals. There may be anynumber of fold lines 120 and 130, which are made by the converter withsufficient penetration of the chipboard to facilitate rolling of thewall section 113 during expansion by the expanding machine. On the otherhand, the use of too numerous fold lines will weaken the integrity ofthe expanded chips and detract from their performance as packagingmaterial. Upon rolling of the wall section 113 into a circular shape,spines 141 are exposed from partial jagged lines 120 and 130. The spinesprotrude outward from the wall section 113, but the wall section remainsattached at common shoulders 121 and 131.

[0056] In addition, a fold line 110 is formed on one portion of wallsection 113 to form a tab 111 between edge 115 and the wall section.Bonding media 117 can be applied to the tab 111 and/or to the matingbonding area 119 for securing the expanded chip in its final shape,shown in FIG. 5.

[0057] As shown in FIG. 6, the converter adds a perforation line 108Xbetween chips 105 (A, B) and 106 (A, B) to enable them to be completelyseparated from one another prior to, during or after the expansion step,as necessary. The separation between chips 105B and 106B isaccomplished, for example, by bursting shoulders 122. A similar line108W can be added to the front of chips 105A and 105B, which as shownare the leading chips on the sheet 102. Similarly, a perforation line108Y is formed between chips 106 (A, B) and 107 (A, B). Again, theseparation between chips 106B and 107B can be accomplished by burstingshoulders 132. As illustrated in the drawing, lines 108W, 108X, 108Y and108Z are zigzag in configuration, so that the edges formed on theseparated and expanded chips will be jagged or serrated, therebyproviding appropriate surfaces for interlocking with other fullyexpanded chips when used as packaging. The lines 108W, 108X, 108Y and108Z could be formed in other configurations that would accomplish thesame result.

[0058] Similarly, the intermediate converter forms a line of weakness116 between the chips in row A (i.e., chips 105A, 106A and 107A) and thechips in row B (i.e., chips 105B, 106B and 107B). The chips in each rowmay be separated from the adjacent chip in the other by bursting line ofweakness 116. Again, line 116 has a zigzag configuration, so that theedge of each chip after separation will be jagged or serrated to aid ininterlocking of the expanded chips.

[0059] As noted previously, the intermediate converter may also addsapertures or holes at various locations on each chip formed on thechipboard. Usually, it is desirable to both cut the hole and to removethe center portion before shipment to the packager to reduce weight.Alternatively, the holes could be preformed by the converter, and thecenter portion removed or just folded in during expansion-on-site by theexpanding machine. The holes may be any shape, e.g., circular,triangular, square or star shaped in configuration. There may bemultiple holes in each section to decrease weight and increaseinterlocking. As described later, the holes interlock with jagged orserrated portions on adjacent chips after the chips are applied around apackaged item to be shipped thereby providing improved blocking, bracingand cushioning characteristics during shipment.

[0060] The bonding media 117 may be any suitable adhesive as describedpreviously with respect to the triangular shaped chip. When the wallsection 113 is rolled up to form the expanded chip, the ends thereof canbe secured using a butt or tab joint as shown in FIG. 5A or a lap jointas shown in FIG. 5B. Obviously, adhesive is applied to the front or backof the tabs as appropriate to secure the chip in its final form.

[0061] As discussed previously, other securing means may be employedincluding connecting features and attachment methods.

We claim:
 1. An intermediate sheet of two or more packing chipprecursors, each chip precursor being separably connected to at leastone adjacent chip precursor and the precursor further comprising: threesections each of which is foldably attached to at least one othersection which sections upon folding each form a side of the packingchip; securing means for securing the sides of the packing chip in acompleted shape selected from the group consisting of bonding media orconnecting features, said shape having a triangular cross-section; andwherein the chip precursor contains one or more apertures on at leastone section configured such that the expanded packing chip formsinterlocking engagement with portions of adjacent packing chips whenemployed as packaging.